Systems and methods for forming handles in furniture

ABSTRACT

Handles for furniture, and in particular handles for mattresses, may be made by, among other things, securing a piece of fabric along the perimeter of the mattress, and more particularly, by securing an excess section of border panel fabric to the side wall of the mattress so that the excess section of border panel forms a handle that can be gripped and manipulated by a user. Embodiments include furniture handles, such as handles for mattresses, cushions, futons and the like. In other aspects, methods for making such handles are shown including methods that secure an oversized border panel to the sidewall of a mattress such that a portion of the border panel can be folded over onto itself and formed into a handle.

CROSS-REFERENCE TO OTHER PATENT APPLICATIONS

This application claims the benefit of U.S. provisional Patent Application No. 60/618,648, filed Oct. 14, 2004, the content of which is incorporated herein by reference in its entirety.

BACKGROUND

From time-to-time, consumers are required to lift and move heavy pieces of furniture either for cleaning the furniture or a rug under the furniture or to change its location. To enable such tasks, furniture pieces are generally equipped with handles. For example, mattresses often come with string or cord handles that either attach or form part of the side regions of the mattress, usually around the center, or at the ends. Even though these string handles are commonplace in mattresses and other furniture, and seem to work fairly well, they suffer from a number of drawbacks.

They are unsightly, somewhat difficult to manufacture and often only well positioned for use by a person of typical size, with a smaller person finding the spacing between handles to be too large to achieve a comfortable grip. Furthermore, string handles are typically affixed tightly to the furniture in an effort to camouflage them and make the furniture more visually appealing. However, this technique limits the handle's adjustability and can provide an uncomfortable grip for the person moving the furniture. A further disadvantage of string handles is they generally need a complex assembly process that can be costly and time-consuming.

Other types of popular handles include looped handles that are either attached superficially to the side border region of a mattress or are somehow linked with the insides of the mattress construction to increase strength. These suffer from similar drawbacks described for string handles. External devices that attach to furniture to aid in lifting and moving are also known. However, these are expensive and cumbersome and easily lost. As such they are not a practical solution for typical household applications.

Accordingly, there is a need for a handle system for furniture that has a large expanse of handle gripping locations, aesthetically blends in with the furniture, and is inexpensive and relatively easy to manufacture and use.

SUMMARY OF THE INVENTION

The systems and methods described herein include improved furniture handles and improved methods for manufacturing furniture handles, such as handles for mattresses.

In one aspect the invention provides handles for furniture and the furniture that has these improved handle systems. In particular, various embodiments include furniture handles, such as handles for mattresses, cushions, futons and the like, where the handle is formed as a flap of fabric that is attached to the sidewall of the mattress or cushion to provide an extension of fabric that can be gripped by a user to move or otherwise manipulate the mattress. In one particular embodiment, these fabric handles extend around the full periphery of the mattress. In other aspects, the invention provides methods for making such handles including methods that secures as oversized border panel to the sidewall of the mattress such that a portion of the border panel can be folded over onto itself and formed into a handle.

More particularly, in one aspect, the systems and methods described herein include methods of forming a handle system for lifting and moving furniture. These methods may comprise the steps of providing a side border piece with dimensions larger than the dimension of the respective side border region of the furniture, and having at least one layer of upholstery and at least one layer of padding that are joined together. The side border piece is attached to at least one respective side border region of the furniture such that an excess piece of side border material folds onto itself to form an overlapped flap, and the portion of the overlapped flap that is closer to the fold is joined to the side border region of the furniture leaving a remaining portion of the overlapped flap to be used as a handle. Optionally, the remaining portion of the overlapped flap is trimmed with at least one layer of material. In such methods the side border region of the furniture may comprise an attached side border piece. The overlapped flap may surround the periphery of the furniture, or surround portions of the periphery of the furniture.

Optionally, a plurality of side border pieces may be attached in opposing orientations to form oppositely overlapped flaps, and the overlapped flaps may be split, separated or cut in at least one location along a direction parallel to the direction of lifting such that the continuum of handles is interrupted to form more than one discrete handle. Additionally, and optionally, the method may include a step of forming a cut in the overlapped flap to provide an aperture through which the user may place their hand or fingers. The cuts may be of rectangular or ovular or any closed form polygonal cuts made in the overlapped flaps and the material enclosed by the polygon to form additional discrete gripping locations. The furniture handle may be used with mattresses, including open coil, pocketed coil, coils in foam, all foam units, one-sided mattresses and two-sided mattresses. One layer of the mattress upholstery and padding are attached together by stitching, adhesive, or thermal bond. The padding may be foam padding.

In another aspect, the systems and methods described herein include systems for bedding. These bedding systems may comprise a mattress, and a side border piece with dimensions larger than the dimensions of the respective side border region of the mattress, and having at least one layer of upholstery and at least one layer of foam that are joined together. The excess piece of side border material folds over onto itself to form an overlapped flap.

In such systems, the overlapped flap may be used as a handle system to lift and move the bedding system. The handle system may comprise a continuum of multiple uninterrupted handles with a plurality of gripping locations. The overlapped flap may surround the periphery of the mattress, or may surround portions of the periphery of the mattress.

Optionally, the overlapped flaps may be split or separated or cut in at least one location along a direction parallel to the direction of lifting such that the continuum of handles is interrupted to form more than one discrete handle. One layer of mattress upholstery and foam are attached together by stitching, adhesive, or thermal bond. Additionally, and optionally, the system may include cuts in the overlapped flap to provide an aperture through which the user may place their hand or fingers. The cuts may be of rectangular or ovular or any closed form polygonal shape made in the overlapped flaps and the material enclosed by the polygon to form additional discrete gripping locations. The mattress may include open coil, pocketed coil, coils in foam, all foam units, one-sided mattresses and two-sided mattresses.

BRIEF DESCRIPTION OF THE DRAWINGS

The following figures depict certain illustrative embodiments of the invention in which like reference numerals refer to like elements. These depicted embodiments may not be drawn to scale and are to be understood as illustrative of the invention and not as limiting in any way.

FIG. 1 is a three-dimensional view of a folded side border piece including an overlapped flap formed from folding an excess piece of side border material.

FIGS. 2A-2D depict perspective views of component parts of a mattress assembly.

FIGS. 3A-3C depict a method of forming a handle in a mattress comprising components shown in FIGS. 2A-2D.

FIG. 4 is a perspective view of an assembled mattress comprising an overlapped flap from at least one side border piece that provides a handle surrounding the periphery of a mattress.

FIG. 5 is a three-dimensional view of an assembled mattress comprising oppositely oriented overlapped flaps formed on opposite sides of the mattress.

FIG. 6 depicts an exploded three-dimensional view of a mattress assembly comprising an overlapped flap and a mattress further comprising a side border piece according to one illustrative embodiment of the invention.

FIG. 7 depicts a method to lift and move an assembled mattress using a handle system according to one illustrative embodiment of the invention.

DETAILED DESCRIPTION OF THE DRAWINGS

These and other aspects and embodiments of the systems and methods of the invention will be described more fully by referring to the figures provided.

The systems and methods described herein will now be described with reference to certain illustrative embodiments, although the invention is not to be limited to these illustrated embodiments which are provided merely for the purpose of describing the systems and methods of the invention and are not to be understood as limiting in anyway. As will be seen from the following description, in one aspect the invention provides handles for furniture and the furniture that has these improved handle systems. In particular, the embodiments illustrated below include furniture handles, such as handles for mattresses, cushions, futons and the like, where the handle is formed as a flap of fabric that is attached to the sidewall of the mattress or cushion to provide an extension of fabric that can be gripped by a user to move or otherwise manipulate the mattress. In one particular embodiment these fabric handles extend around the full periphery of the mattress. In other aspects, the invention provides methods for making such handles including methods that secures as oversized border panel to the sidewall of the mattress such that a portion of the border panel can be folded over onto itself and formed into a handle.

FIG. 1 depicts a first embodiment of the handle devices described herein, and in particular depicts a three-dimensional view of a portion of a handle 100 including an overlapped flap 108 formed from folding an excess piece of side border panel 106 on to itself. The side border panel 106 includes at least one layer of upholstery 102 and at least one layer of padding 104 that are joined together by stitching 114. The side border panel 106 folds onto itself to form the overlapped flap 108. The overlapped flap 108 is joined to the side border piece 106 by stitching 110 and 112 such that an overlapping welt 120 is formed. The edge of the overlapped flap 108 is trimmed with a layer of material 116 joined by stitches 118.

The upholstery 102 and the padding 104 may be joined together typically by stitching, adhesion or thermal bonding. The upholstery material 102 and padding 104 may be joined together at many different locations and in FIG. 1 upholstery material 102 and padding 104 are shown as being joined by lines of stitching 114, 112 and 110. The padding 104 may be foam such as polyurethane foam, latex, or any other suitable material and the upholstery 102 may be any suitable fabric including but not limited to polyester, Nylon and cotton. Stitches 110 and 112 provide structural support to increase the strength of the handle 100 by attaching the overlapped flap 108 to both the side border piece 106 as well as the furniture side border region. Optionally, the handle 100 may also be secured to any mattress frame or border assembly, including border rods, wires, and/or side foam rails. The location of stitches 110 and 112 may be modified, particularly to adjust the size of the overlapping welt 120, and generally to suit the needs of a piece of furniture. The lower portion of the overlapped flap 108 comprising the trimming 116 may be used as a handle grip. Trimming 116 may be customized for gripping convenience including the use of rubber grips, cushioned padding or upholstery material. In one embodiment, in addition to trimming 116, cord or string is passed through the loop formed from the trimming material and extends along the length of the overlapped flap such that the weight and rigidity of the cord or string helps maintain the structure and the aesthetic appeal of the handle system 100. The overlapped flap 108 may be separated or cut perpendicular to stitches 110 and 112 such that multiple separate overlapped flaps may be formed resulting in a plurality of independently movable handles.

For the depicted handle 100, the component parts such as the upholstery 102 and the foam 104 may be conventional materials and components used in mattress manufacturing. For example, the upholstery 102 may be Nylon, cotton, polyester or any suitable material. The foam 104 may be polyurethane, as noted above, as well as Latex, Neoprene or another suitable material. Optionally and additionally strengthening material, such as a layer of polyvinyl chloride, a set of Kevlar™ fibers or other material may be provided as a layer that is disposed under or otherwise adjacent the foam 104 and upholstery 102. This additional and optional strengthening layer provides additional strength for the handle 100 for those applications where the object is heavy and additional support is desirable. One example may be for a king size mattress which can weigh over 200 lbs. Optionally and additionally to providing a strengthening layer, stitches 110 and 112 can be any suitable fiber with high tensile strength such as Nylon such that the handle system 100 maintains structural integrity during operation. Stitches 110 and 112 may be distributed non-uniformly such that there are more stitches in certain locations that are more likely to be used for gripping and fewer stitches in other locations along the side border of the mattress. Another optional and additional layer of fire resistant material, such as Kevlar™ FR barrier that is disposed under or otherwise adjacent the foam 104 and upholstery 102 may be used in any furniture cushion, including car seats, sofa cushions, and futons.

FIGS. 2A-2D show perspective views of component parts of a mattress assembly used to form the handle according to the invention. The mattress assembly includes a mattress 122 of FIG. 2A and side border panels comprising side fabric 130 of FIG. 2B, padding 132 of FIG. 2C and upholstery 134 of FIG. 2D. Mattress 122 comprises a foam encasement outer shell 124 and internal structural components 126 such as spring coils.

In particular, FIGS. 2A-2D show a mattress 122 in a partially assembled condition with side border panel components shown in FIGS. 2B-2D as unattached and being spaced away from the body of the mattress 122. As shown in FIGS. 2A-2D the side border panels may attach to each side of the mattress 122 body including the sides, head and foot. In the depicted embodiment, side panels are only shown as being on one lengthwise side 128 of the mattress 122, but it should be apparent to one of ordinary skill in the art that additional side border pieces may attach to the opposite lateral side, head side and foot side of the mattress 122. In one embodiment, at least one piece of fabric on padding 130 surrounds the periphery of the mattress 122. In one embodiment, at least one piece of padding 132 and upholstery 134 surround the periphery of the mattress 122. In one illustrative embodiment, the padding 132 and the upholstery 134 shown in FIGS. 2C and 2D, respectively, are formed larger along at least one dimension than the corresponding dimension on the lengthwise side 128 of the mattress 122. In another embodiment, the padding 132 is formed of same dimensions as a side of the mattress and the upholstery 134 is formed of larger dimensions. The coils 126 could be at least one of open coils, pocketed coils or coils in foam. The hard outer shell 124 could be hardened foam and can be formed from at least one piece of material. Furthermore, the mattress 122 could be one-sided or two-sided by design. The upholstery 134 and the padding 132 can be conventional materials and components used in mattress manufacturing. For example, the upholstery 102 can be Nylon, cotton, polyester or any suitable fabric material. Padding 132 may be foam formed from polyurethane, as noted above, as well as Latex, Neoprene or another suitable material.

FIG. 3A-3C depict a method of forming a handle in mattress assembly comprising the components shown in FIGS. 2A-2D. The mattress 136 includes at least one soft sleeping surface 138 and a side wall covered with a material similar to the material 130 of FIG. 2B, around the periphery of a mattress similar to mattress 122 of FIG. 2A.

FIG. 3A depicts the assembly of a side border panel 150 onto a side border region of a mattress 136. The side border panel 150 comprises at least one layer of upholstery and at least one layer of padding and at least one optional additional layer of material for increased strength and fire resistance. As shown, the side border panel 150 is wider than the corresponding dimension of the mattress 136. In the embodiment depicted, the side border panel is about twelve inches (30 cm) wider. The excess portion of the side border panel 150 is provided to allow this portion to be folded over and formed into a handle. The amount of excess material provided will depend in part on how wide the handle is to be made, how many times the material is to be folded and other similar aspects of the particular embodiment. The lower portion 140 of the side border panel 150 is directly attached to the side border region of the mattress 136. Stitches 142, 144, 146 and 148 indicate locations for attachment. Other means and locations for attachment could also be implemented without departing from the scope of the invention. In the depicted embodiment, side border panels are only shown as being on one lengthwise side of the mattress 136, but it should be apparent to one of ordinary skill in the art that additional side border pieces may attach to the opposite lateral side, head side and foot side of the mattress 136.

FIG. 3B depicts the folding of the upper portion of the side border panel 150 of FIG. 3A to form an overlapped flap 152. In one illustrative embodiment, the overlapped flap 152 is formed from folding the upper portion of the side border panel 150 in the direction of the arrows 154 and 156. The size of the overlapped flap 152 can be adjusted according to specific needs by moving it either in the direction of arrows 154 and 156 or in an opposite direction.

FIG. 3C depicts the formation of a handle by securely attaching the top portion of the overlapped flap 152 to itself and the underlying mattress side border region. In one illustrative embodiment, the overlapped flap 152 is attached by stitching 160 such that an overlapping welt 158 is formed on the top portion of the side border panel 150. In one embodiment, the bottom portion of the overlapped flap 152 may be used as a handle grip. In one embodiment, the bottom handle portion of the overlapped flap 152 may be customized for gripping convenience including trimming with rubber molded grips, cushioned padding or upholstery material. The overlapped flap 152 may also be separated or cut perpendicular to stitches 160 such that multiple separate overlapped flaps may be formed resulting in a plurality of independently movable handles.

In one embodiment, a single continuous handle may be employed such that the side border panel comprising at least one layer of upholstery and at least one layer of padding is one continuous entity and the overlapped flap formed therefore surrounds the periphery of the object. In another embodiment, the method shown in FIGS. 3A-3C is repeated for at least one additional side border region of the mattress 136.

FIG. 4 is a side perspective view of one embodiment of an assembled bedding system 162 comprising at least one overlapped flap 166 from at least one side border piece 164, surrounding the periphery of a mattress 136. The overlapped flap 166 is disposed about half way down the sidewall of the mattress 138. The lower portion of the overlapped flap 166 is trimmed with material 168. The upper portion of the overlapped flap forms an overlapping welt 170.

FIG. 4 shows that the single continuous overlapped flap 166 provides a continuum of gripping locations formed all around the periphery of a mattress assembly 162. This single continuous overlapped flap 166 could be split or separated perpendicular to the structural stitches 172 and 174 such that multiple separate overlapped flaps may be formed resulting in a plurality of independently movable handles.

FIG. 5 is a three-dimensional view of a two-sided mattress assembly 176 comprising oppositely oriented overlapped flaps 178 and 180 formed on at least one side of the mattress 136 according to another embodiment. The overlapped flaps 178 and 180 are formed from folding an excess piece of side border material 182 on two sides. The construction of such a handle system comprising a side border piece 182 and two oppositely oriented overlapped flaps 178 and 180 is similar to the construction of a handle system 100 shown in FIG. 1 with each of the two overlapped flaps in FIG. 5 similar to overlapped flap 108 in FIG. 1. Overlapped flaps 178′ and 180′ are similarly constructed on the opposite lateral side border region of the mattress 136. Velcro™ straps 184 are attached to the inside surface of the overlapped flaps 178, 178′, 180 and 180′ such that they can be securely stowed when not in use.

Mattress assembly 176 is a two-sided mattress and as such it often becomes necessary to lift and rotate the sleeping surfaces of the mattress assembly. The straps 184 prevent the overlapped flaps 178 and 180 from falling over when they are on the side of the mattress 136 not being used. Other means of attachment could also be used without departing from the scope of the invention. Similar to the mattress assembly 162 shown in FIG. 4, mattress assembly 176 could include two continuous overlapped flaps that are attached around the periphery.

FIG. 6 depicts an exploded three-dimensional view of a mattress assembly 186 comprising an overlapped flap 190 and a mattress 194. The mattress 194 includes a sleeping surface 196 and side border regions 188 with an existing side border panel attached. The overlapped flap 190 comprises at least one layer of upholstery and is attached to the side border region 188 by stitches 192.

In the mattress assembly 186 of FIG. 6, the overlapped flap 190 is a piece of fabric that can directly attach to an existing side border panel 188. There could be a plurality of such overlapped flaps 190 around at least one portion of at least one side of the mattress 194. It can be further split or separated to form a plurality of discrete overlapped flaps that serve as a multitude of discrete gripping locations.

FIG. 7 depicts a method to lift and move a mattress assembly 198 using overlapped flaps 202 and 204 according to one illustrative embodiment of the invention. The mattress assembly includes a mattress 200 and at least one overlapped flap 202 and 204 covering portions of at least two side border regions 210 of the mattress 200. Shown in FIG. 7 are two persons 206 and 208 gripping the lower portion of the overlapped flaps 202 and 204 respectively and unfolding it upwards to lift the mattress 200.

The overlapped flaps 202 and 204 are shown to be formed on two opposing lengthwise lateral side regions of the mattress. In one embodiment, additional overlapped flaps with gripping locations are formed on the head and foot side border regions of mattress 200 such that at least two additional persons can help with moving mattresses that are heavy or other difficult to move or manipulate. In another embodiment, holes are made at multiple locations along the length of the overlapped flap such that other lifting devices may lock in and lift and move the mattress 200.

In another aspect, the invention provides methods for manufacturing furniture handles and for manufacturing cushions, such as sofa cushions and mattresses having such handles. The handles may be manufactured as described above and used to form the mattresses and other products described.

Therefore, it may be seen that, among other things, a furniture handle, and in particular handle for a mattress, is provided which provides improved usability and manufacturability. While this invention has been described in specific detail with reference to the disclosed embodiments, it will be understood that many variations and modifications may be effected within the spirit and scope of the invention as described in the appended claims. For example, the mattresses may have two or more handles, located a different positions on the mattress. The handles may be provided on mattresses and other cushions, as well as on foundations, and other furniture frames that are typically upholstered, to provide these frames with an easy to use handle. The handles described herein may be used with any type of mattress, including a foam core mattress, or a mattress having a combination of foam and springs. The mattress may be one-sided or two-sided, and the number of handles provided may vary based on the number of sleeping surfaces of the mattress. In light of the all that is disclosed above, those skilled in the art will know or be able to ascertain using no more than routine experimentation, many equivalents to the embodiments and practices described herein. Accordingly, it will be understood that the invention is not to be limited to the embodiments disclosed herein, but is to be understood from the following claims, which are to be interpreted as broadly as allowed under the law. 

1. A method of forming a handle system for lifting and moving furniture, comprising the steps of: providing a side border piece with dimensions larger than the dimension of the respective side border region of the furniture, and having at least one layer of upholstery and at least one layer of padding that are joined together, attaching at least one side border piece to at least one respective side border region of the furniture such that an excess piece of side border material folds onto itself to form an overlapped flap, joining a portion of the overlapped flap that is closer to the fold, to the side border region of the furniture leaving a remaining portion of the overlapped flap to be used as a handle, and trimming the remaining portion of the overlapped flap with at least one layer of material.
 2. A method as in claim 1 wherein the side border region of the furniture further comprises an attached side border piece.
 3. A method as in claim 1 wherein the overlapped flap surrounds the periphery of the furniture.
 4. A method as in claim 1 wherein the overlapped flap surrounds portions of the periphery of the furniture.
 5. A method as in claim 1 wherein a plurality of side border pieces are attached in opposing orientations to form a plurality of oppositely overlapped flaps.
 6. A method as in claim 1 wherein the overlapped flap is split or separated or cut in at least one location along a direction parallel to the direction of lifting such that the continuum of handles is interrupted to form more than one discrete handle.
 7. A method as in claim 1 wherein a plurality of rectangular or ovular or any closed form polygonal cuts are made on the overlapped flaps and the material enclosed by the polygon is removed to form additional discrete gripping locations.
 8. A method as in claim 1 wherein the furniture includes mattresses
 9. A method as in claim 8 wherein the mattress comprises at least one of open coils, pocketed coils, coils in foam, all foam units, one-sided mattresses and two-sided mattresses.
 10. A method as in claim 8 wherein the at least one layer of upholstery and the at least one layer of padding are attached together by stitching, adhesive, or thermal bond.
 11. A method as in claim 1 wherein the padding includes foam.
 12. A bedding system comprising: a mattress, and at least one side border piece with dimensions larger than the dimensions of the respective side border region of the mattress, and having at least one layer of upholstery and at least one layer of foam that are joined together and wherein an excess piece of side border material folds over onto itself to form an overlapped flap.
 13. A bedding system as in claim 12 wherein the overlapped flap is used as a handle system to lift and move the bedding system, the handle system comprising a continuum of multiple uninterrupted handles with a plurality of gripping locations.
 14. A bedding system as in claim 12 wherein the overlapped flap surrounds the periphery of the mattress.
 15. A bedding system as in claim 12 wherein the overlapped flap surrounds portions of the periphery of the mattress.
 16. A bedding system as in claim 13 wherein the overlapped flap is split or separated or cut in at least one location along a direction parallel to the direction of lifting such that the continuum of handles is interrupted to form more than one discrete handle.
 17. A bedding system as in claim 12 wherein the at least one layer of upholstery and the at least one layer of foam are attached together by stitching, adhesive, or thermal.
 18. A bedding system as in claim 12 wherein a plurality of rectangular or ovular or any closed form polygonal cuts are made on the overlapped flaps and the material enclosed by the polygon is removed to form additional discrete gripping locations.
 19. A bedding system as in claim 12 wherein the mattress comprises open coils, pocketed coils, coils in foam, all foam units, one-sided mattresses and two-sided mattresses. 